Cold chain packaging

ABSTRACT

A method of making a cold chain package, includes, providing corresponding rolls of dissimilar insulating packaging material; forming separate panels from sheets of dissimilar insulating packaging material provided by the corresponding rolls; enclosing the panels in a membrane, the membrane defining a hinge between the panels that are adjacent to each other; and folding the panels along each hinge to form a box-shaped chamber.

This application is a divisional of U.S. patent application Ser. No.12/508,803, filed Jul. 24, 2009, which claims priority under 35 USC119(e) from Provisional Application 61/083,814 filed Jul. 25, 2008.

BACKGROUND

The present invention relates generally to thermally insulatedpackaging, and more specifically to packaging designed for maintainingpackaged items in a refrigerated state.

There is an increasing demand for so-called “cold chain” packaging thatis suitable for maintaining items at temperatures in the range of 34-48°F. for at least as long as 8 days. Typical items shipped via cold chainpackaging include pharmaceuticals, foodstuffs and similar perishableitems.

Conventional cold chain packaging typically consists of an outercontainer, such as a corrugated carton, provided with a lining of eitherStyrofoam or resilient foam in the form of formed, molded or precutpads, and at least one pre-chilled gel pack, which is a sealed bag-likecontainer of heavy plastic filled with a gel which freezes upon chillingand maintains a relatively low temperature in the container. Anexemplary cold chain package is sold by TCP Reliable(www.tcpreliable.com) under the “Timesaver” brand. When a package isdesired that has a longer cooling period, a larger outer container isprovided, and more layers of foam and gel packs create a thickerinsulated compartment.

Thus, current cold chain packaging is limited by size of the packageand/or the length of time items can be kept cold. Also, conventionalcold chain packages are largely single use, and as such areenvironmentally inefficient.

SUMMARY

The present cold chain package includes an arrangement of layers havingdissimilar materials that keeps shipped items that need to be kept coldat a designated temperature for a longer period of time than existingpackaging. This allows such items to be shipped via groundtransportation, i.e., truck, as well as air transportation. The packageis also reusable and has a compact design that saves space and minimizesthe size of the shipping containers needed to ship items.

Specifically, the present cold chain package includes a plurality ofpanels surrounded by an overwrap, where each of the panels includes aplurality of layers of dissimilar materials. The package also includes ahinge formed between adjacent panels of the plurality of panels forfacilitating folding of the panels to fit in a shipping container.

Another embodiment provides a method of making a cold chain package thatincludes providing corresponding rolls of dissimilar insulatingpackaging material, forming separate panels from sheets of dissimilarinsulating packaging material provided by the corresponding rolls,enclosing the panels in a membrane where the membrane defines a hingebetween the panels that are adjacent to each other, and folding thepanels along each hinge to form a box-shaped chamber.

A further embodiment provides a method for distributing cold chainpackaging that includes producing and assembling a cold chain packagehaving a pre-printed address identifier that identifies a shippinglocation, inserting a cold chain package and an article to be deliveredin a shipping container at the shipping location, the cold chain packagemaintaining the article at a desired temperature during shipping,delivering the shipping container to a designated location, returningthe cold chain package to the shipping location identified by thepre-printed address identifier via a package courier and reusing thecold chain package in another shipping container.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an overhead plan view of a disassembled package incorporatingthe present invention;

FIG. 2 is a schematic sectional view of the package of FIG. 1 takenalong the line 2-2 of FIG. 1 in the direction generally indicated;

FIG. 3 is an overhead plan view of the present package shown assembled;

FIG. 4 is a schematic representation of a production line suitable foruse in manufacturing the composite packaging material used in thepresent package; and

FIG. 5 is a schematic representation of a distribution system suitablefor use with the present package.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIGS. 1-3, the present composite cold chain package isgenerally designated 10 and is made of a web 12 formed, as by diecutting or similar technology into designated panels including front 14,bottom 16, left side 18, right side 20, rear 22 and top 24. Overlyingeach panel 14-24 is a bag-like membrane 26, preferably of a heavy gaugepolyethylene overwrap that is heat sealed to form a hinge 26 a betweenadjacent panels. It is contemplated that the overwrap material maychange depending on the application. The hinge 26 a facilitates thefolding of the panels 14-24 into a box shape forming a cold-chainchamber 28. An advantage of the overwrap 26 is that, after each use, thepackage web 12 can be cleaned with disinfectant to address microbialgrowth resulting from condensation during shipment.

A feature of the present package 10 is that it occupies significantlyless space than conventional cold chain packaging for obtaining adesignated degree of insulation lasting a specified amount of time. Thismore efficient cooling power is achieved by creating a composite ofdissimilar materials formed into each of the multi-layer panels 14-24.Some of the layers in the present package 10 are novel combinations ofotherwise conventional packaging materials.

Referring now to FIG. 2, the preferred layers, which are schematicallyshown, include material A, including a combination of a sheet ofaluminum foil 30 laminated to a corresponding sheet of Bubble Wrap®brand cushioning material 32, with a transition material 34therebetween. Suitable cushioning material of this type is manufacturedby Sealed Air Corp., www.sealedair.com under the trademark TEMPSHIELD™.As is known in the plastic thermoforming arts, transition materialsfacilitate thermal bonding between otherwise dissimilar materials. Arepresentative transition material 34 is a heat sealable polyethylene orpolyvinylchloride (PVC). A second optional insulating layer is materialB, including a combination of preferably polyethylene closed cell foam36 to which is laminated a sheet of aluminum foil 38 with a transitionlayer 40 therebetween. Suitable material is also manufactured by SealedAir Corp under the designation CA-250. It is preferred that the foil 38face the interior of the package 10.

Still another optional layer is material C, which is approximately 1inch thick foam, preferably closed cell polyurethane foam; however otherfoams are considered suitable and the thickness may vary. Yet anotheroptional layer is material D, including a layer of Mylar® polyester film42 laminated to a sheet of fiberfill synthetic filling material 44 witha transition layer 46 therebetween. In some cases, an additional layerof transition material (not shown) may be placed upon the Mylar® film 42on the opposite side from the transition layer 46.

As seen in FIG. 2, the web 12 is preferably made of a composite ofmaterials in layers as follows: DABABAB. It will be appreciated that thenumber, orientation and arrangement of layers may vary to suit thesituation. It is also contemplated that at least some of the layersDABABAB may be secured to each other as by heat sealing, or the layersmay be loosely contained within the overwrap 26.

Referring now to FIG. 3, upon assembly, the web 12 is folded into anouter container 50, typically a corrugated carton so that each of thepanels 14-24 is associated with a panel of the container. The folded web12 forms the cold chain chamber 28 into which an article to be shipped52 is placed, preferably surrounded by pre-chilled gel packs 54. It hasbeen found that the assembled panels, 14-24, each much thinner thanconventional cold chain packaging, have a thickness in the range of1.5-2.5 inches. It will be understood that the thickness may vary withthe number of layers and the combination of composite materialsselected. In any event, the package 10 is significantly thinner thanconventional cold chain packages with similar temperaturemaintenance/insulation capabilities. Despite this relatively thinprofile, the package 10 has been shown to retain a temperature of 48° F.for at least eight days.

Referring now to FIG. 4, a schematic of the production of the compositelayers of materials A, B and D is shown. A supply of each of theinsulating materials, such as foam, Bubble Wrap® cushioning material,aluminum foil, foam, Mylar® film, etc. is each provided in a respectiveroll 58, 60. The transition material 34, 40, 44, 46 is also provided ina roll 62. A rack 64 is created to arrange the rolls 58, 60, 62 so thatthe components of the composite material are arranged in a web formatthat is placed on a conveyor table 66 which conveys the layers to a heatsource 68, where they are laminated together. After lamination, thecomposite material is placed upon a take up roll 70.

Referring now to FIG. 5, besides having reduced weight and bulk comparedto conventional cold chain packaging having similar temperatureinsulation qualities, another feature of the present package 10 is thatit is reusable. A network of collection and refurbishing facilities isenvisioned for facilitating the reuse of such packages, further reducingthe cost to the shipper. The smaller size of the present packagefacilitates such shipment.

More specifically, the present network, generally designated 80,includes a Distribution Center 82 where the packages 10 are produced byassembling the webs 12 into packages and inserting the packaged articles52. The packages 10 are shipped by courier, such as UPS, FedEx, USPS andthe like to an end user 84. Due to the longer temperature retentionproperties of the present cold chain packaging, the shipping process canbe extended to at least as long as 7 days. Thus, goods which previouslyhad to be shipped by air can now travel by ground.

Since the packages 10 have preprinted return labels, bar codeidentification, RFID tags or similar identifiers, the end user 84 canreturn them to the Distribution Center 82, or to a Refurbishing facility86, where the package is disassembled, checked for damage andreassembled as needed prior to reshipment in bulk to the DistributionCenter 82. In this manner, the packaging is reused numerous times,reducing packaging and shipping cost compared to conventional cold chainpackaging technology. Due to the identifiers, the Distribution Center 82can grant credits, discounts, rewards or other incentives to the enduser 84 to encourage return of the packages 10. Conversely, the sameidentifiers can be used so that the end user 84 is charged if thepackage 10 is not returned.

While a particular embodiment of the present cold chain package has beendescribed herein, it will be appreciated by those skilled in the artthat changes and modifications may be made thereto without departingfrom the invention in its broader aspects and as set forth in thefollowing claims.

1. A method of making a cold chain package, the method comprising:providing corresponding rolls of dissimilar insulating packagingmaterial; forming separate panels from sheets of dissimilar insulatingpackaging material provided by said corresponding rolls; enclosing saidpanels in a membrane, said membrane defining a hinge between said panelsthat are adjacent to each other; and folding said panels along each saidhinge to form a box-shaped chamber.
 2. The method of claim 1, whereinsaid insulating packaging material includes at least one of foam, foamlaminated to foil, cushioning material laminated to foil and polyesterfilm laminated to fiberfill filling material.
 3. The cold chain packageof claim 1, further comprising forming said panels to have a thicknessof 1.5 to 2.5 inches.
 4. A method for distributing cold chain packagingcomprising: producing and assembling a cold chain package having apre-printed address identifier that identifies a shipping location;inserting a cold chain package and an article to be delivered in ashipping container at the shipping location, the cold chain packagemaintaining the article at a desired temperature during shipping;delivering the shipping container to a designated location; returningthe cold chain package to the shipping location identified by thepre-printed address identifier via a package courier; and reusing thecold chain package in another shipping container.
 5. The method of claim4, further comprising at least one of the steps of checking the coldchain package for damage and repairing the cold chain package prior toreusing the cold chain package.